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Worldwide Pollution

Control Association

FirstEnergy ESP Seminar

November 27th 28th, 2007

Visit our website at www.wpca.info

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Precipitator Maintenance and

Operations

By Scott Williams

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External Dust Collection

Concerns

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Preheater Basket

Material Can

Ground Out

Precipitators

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Carbon Loss on Ignition Decreases Collection Capability

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Carbon Loss on Ignition Increases Emissions and Opacity

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Proper Gas Flow is Critical

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Ash Build-up on Turning Vanes in the Duct Causes Poor Gas

Flow

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Ash Build-up at Precipitator Inlet

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Ash Buildup at Access Door

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High Voltage Arcing and

Tracking Causes ComponentFailures

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Knife Blade Switch Arcing and High Voltage Cable Failure

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Power Path High Voltage Failure

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Broken High Voltage Insulator

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Tracked Post Insulator Inside a T/R Set

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Support Insulator inside T/R - Tracking

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High Voltage Insulator Tracking

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Water/Air Leakage is a Major

Concern

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A Hole in the Precipitator Hot Roof due to ThermalStress/Corrosion

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Holes in the Side of the Precipitator Due to Corrosion

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Water Leaks From Ductwork

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High Voltage Guard Air Leakage

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Corrosion of High Voltage Guard Due to Air Leakage

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Water Leakage Around Rapper Boot Seal

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Ash Buildup in Hopper

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Water Leakage Through the Precipitator Roof

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Roof Corrosion Due to Water Standing for a Long Period of

Time

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Corrosion Around Access Door

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Thermal Stress Concerns

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Structural Component Bowing due to Thermal Stress

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Plate Bowing Due to Thermal Fatigue

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Thermal Stress Crack in Casing

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Center Wall Cracking

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Thermal Fatigue Cracking At Turning Vane Support

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Mechanical Component Failures

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Hopper Baffle Door- This causes increased opacity

B t St t l C B i

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Bent Structural Cross Brasing

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Baffle Component Failure- Gas will bypass the baffle

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Cracked Plate- Mechanical Stress

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Crack Plate

C k Pl S d

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Crack Plate Swords

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Cracked Plate on top

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Plate Repairs

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Weld Failure At Top of Plate

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Channel Cracking at Top of Plate

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Insulation Problems

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Poor Insulation Can Promote Corrosion

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Plate to Wire Clearances are

Important

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The Wire/Electrode Carries the Charge

The Plate Collects the Ash

Plate to Wire Clearance is Critical

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Rapper Failures

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Rapper Shaft Cracked at Anvil Beam- Shaft has fell down

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Broken Rapper Shaft- In the Penthouse

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Broken Tumbling Hammer

Chain of Tumbling Hammer Sprocket

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g p

Vibrator Shaft Broken

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Vibrator Shaft Broken

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Operational Problems

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Ammonia System Ash Buildup

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Ash Hopper Overfilled

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Ash Buildup on Electrodes- Opacity Can Increase

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Structural Erosion

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Erosion Due to Ash if Flue Gas on Structural Support

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T/R Set Oil Leakage

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Start Up Procedure

Back section should be energized first atstart of first mill operation.

Sections added as needed.

Start SO3 injection at 125oC.

Start NH4 injection when SO3 effects are

evident (usually the next day).